GB2535193A

GB2535193A - Tool for curing a composite component

Info

Publication number: GB2535193A
Application number: GB1502323.7A
Authority: GB
Inventors: Potts Nicholas; Biswas Bhaskar
Original assignee: Zodiac Seats UK Ltd
Current assignee: Safran Seats GB Ltd
Priority date: 2015-02-12
Filing date: 2015-02-12
Publication date: 2016-08-17
Also published as: US11724469B2; US20220219413A1; US11305499B2; GB201502323D0; EP3064342A3; ZA201600845B; EP3064342B8; EP3064342A2; US20160236454A1; EP3064342B1; EP3597415A1

Abstract

A tool 1 for curing a composite component comprises a lay-up surface 7 for laying-up layers of an uncured composite component, a cover assembly 9 comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a sealed zone, and a vacuum port 25 for providing a vacuum to the sealed zone, wherein the tool further comprises at least one heating element 15, 53 within the sealed zone for heating the uncured composite component. The cover assembly may comprise a heating element, or heating blanket. The lay-up surface may comprise a surface heating element. The sealable cover may be a flexible material such that it flexes when a vacuum is provided. A tool wherein the sealable cover comprises a shaped cover that holds its shape is also provided. A tool wherein the lay-up surface is provided with a number of raised portions and/or a number of attachment points for attaching raised portions is also provided. The invention also provides a method of manufacturing a composite component and a composite component. The composite component may form at least part of a piece of aircraft furniture, such as an aircraft seat shell.

Description

Tool for Curing a Composite Component

Background of the Invention

The present invention concerns a tool for curing a composite component, the tool comprising a lay-up surface for laying-up layers of an uncured composite component. The invention also concerns a method of manufacturing a composite component and a composite component. The composite component may form at least part of a piece of aircraft furniture, such as an aircraft seat shell.

Seat shells for aircraft are often manufactured using composite laminate materials. The reason for using composite materials in the structure mostly is due to its lightweight and superior strength-to-weight properties of the material. These composite materials could be monolithic or sandwich composite laminates or a combination. The constituent materials for monolithic composite laminates are pre-impregnated materials (prepregs of resin impregnated fibres) whereas for sandwich composite laminates they are prepregs and a core material (e.g. honeycomb, foam). Honeycomb materials are preferable as a core material. Prepregs may be made with glass and/or carbon fibres impregnated with thermoset resin (e.g. phenolic or epoxy resin). The honeycombs core may be made with aramide based paper. Prepregs are often stored in freezers to ensure they are kept under the correct conditions.

The composite materials are prepared in a clean room by laying up the prepregs (and cores) on a mould tool at room temperature. After being layed-up the composite materials are bagged up using a polytetrafluoroethylene (PTFE) release film (if required), a rubber intensifier layer (to enable a uniform pressure to be applied on the composite comoonent), a breather layer (to absorb excess resin) and then nylon bagging materials. A vacuum is then applied through a port in the nylon bagging (known as de-bulking). The mould tool with these bagged up materials is transferred to an oven or autoclave where the materials are connected to a different vacuum port and taken through a heating cycle (typically, heating to 135°C and remaining at that temperature for a certain period of time depending upon the prepregs, typically 1 hour for phenolic resin prepregs) to cure the material. The materials are allowed to cool down to room temperature before extracting the cured and moulded laminate off the tool.

Following the curing of the material, the moulded part is machined into the required shape and profile as per the engineering design and then passed through an assembly line to attach metal and plastic bonding attachments, cushions and electrical components to complete the seat structure for the aircraft.

This process has many disadvantages. For example: 1) The process can be very long, and therefore expensive, due to operating and man power costs. For example, a. Laying-up of the part can take up to 1.5 days due to the difficulties in laying-up prepregs, particularly when it is required to drape them over complex curved profiles.

b. Moving layed-up composites in and out of the oven or autoclave can take 4 to 5 hours, due to the number of different components being cured in the oven or autoclave at once, and the need to attach each to its own vacuum supply in the oven or autoclave. Also, other components cannot be moved into or out of the oven or autoclave during the curing process, meaning there is a significant lead time in waiting for the oven or autoclave to be empty.

c. The curing process can take 3 hours as the oven or autoclave can take a while to heat up to the desired temperature.

d. CNC machining of the cured composite component can take up to half a day but the lead time in waiting for a machine may be half to 1.5 days.

e. CNC (and other) machining of the cured component can produce a lot of dust, which needs to be extracted using a dust extraction system.

f. It is time-consuming to apply the nylon bagging as it needs to be carefully sealed each time, using a sealant.

g. Transferring the component to and from the CNC machine takes time.

2) The nylon bagging is not reusable and so creates waste.

3) An oven or autoclave is expensive and takes up a lot of space.

4) Laying-up may require the use of separate heating ovens, guns or blankets.

5) Separate vacuum supplies are required for de-bulking and during curing in the autoclave.

6) The process consumes a lot of energy and the equipment requires a large amount of maintenance.

The present invention seeks to mitigate the above-5 mentioned problems. Alternatively or additionally, the present invention seeks to provide an improved tool for curing a composite component.

Summary of the Invention

The present invention provides, according to a first aspect, a tool for curing a composite component, the tool comprising a lay-up surface for laying-up layers of an uncured composite component, a cover assembly for moving in relation to the lay-up surface to cover a layed-up uncured composite component on the lay-up surface, the cover assembly comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a sealed zone, and a vacuum port for providing a vacuum to the sealed zone, wherein the tool further comprises at least one heating element within the sealed zone for heating the uncured composite component.

Providing a tool with an "in-built" heating element allows the layers of uncured composite to be layed-up onto a warm lay-up surface, making lay-up quicker. There is also no need for separate and/or time-consuming heating equipment, such as a heating gun, oven or blanket.

In addition, the tool can be used for the curing process. The tool heats up more quickly to the desired temperature than an oven or autoclave, as the heat is provided within the sealed zone. The volume to be heated is also a lot smaller than the volume of a typical oven or autoclave.

The tool also takes up much less space and is cheaper than a typical autoclave. Typically, the tool may be portable and may be provided with holes for allowing it to be lifted by a fork-lift, or similar.

In addition, providing a moveable cover assembly and sealable cover allows a seal to be established around the uncured component quickly and easily. It does not require a separate sealant.

Further, there is no movement of the tool into and out of an oven or autoclave required. Also, the same vacuum source can be used for both de-bulking and curing.

The layers of the uncured composite component are typically prepregs layers. The composite component may be a monolithic or a sandwich component.

The lay-up surface may be formed of a composite 25 material, such as a carbon fibre composite.

Preferably, the cover assembly comprises a cover heating element for heating an upper side of the layed-up uncured composite component.

More preferably, the cover heating element is attached to an underside of the sealable cover.

Preferably, the cover assembly is provided with an 5 insulating layer (above the cover heating element) to prevent heat from the cover heating element escaping out of the cover assembly.

Preferably, the cover heating element comprises a 10 heating blanket, for example formed of a wire mesh, or similar, embedded within a carrier material.

Preferably, the lay-up surface comprises a surface heating element for heating a lower side of the layed-up uncured composite component. This surface heating element could also be used to warm the layers during laying-up by heating the surface above ambient temperature. For example, the surface could be heated to a temperature of 40 to 50°C.

More preferably, the surface heating element is embedded beneath a top layer of the lay-up surface.

Providing heating elements on the upper and lower sides of a composite component allows more even heating and a more 25 uniform composite structure.

The tool preferably further comprises a vacuum source, such as a vacuum pump, connected to the vacuum port.

Preferably, the vacuum port is provided in the cover assembly.

A vacuum port may, additionally or alternatively, be provided at the lay-up surface.

Preferably, the sealable cover is a shaped cover that holds its shape. The sealable cover therefore has a volume associated with it for containing the uncured composite component.

More preferably, the sealable cover is shaped such that it has a lower edge region that can seal around the lay-up surface and a roof region that holds its shape to extend above the lay-up surface.

Preferably, the sealable cover is supported by a frame structure. The frame makes the sealable cover easier to move and provides a guide to move the sealable cover over the lay-up surface (to move it on to or off from the lay-up surface).

The frame may comprise a hinge to enable the sealable cover to be pivoted over the lay-up surface. The frame structure may comprise a gas strut to aid lifting/pivoting up of the frame and/or to maintain the frame and sealable cover in a position away from the lay-up surface, for example during lay-up. The frame structure may be provided with at least one handle. This aids with control of moving the frame and the cover.

Preferably, the sealable cover is made of flexible material such that it flexes when the vacuum is provided to the sealed zone.

More preferably, the sealable cover is made of an elastomeric material. For example, the sealable cover may be made from a silicon based elastomeric material, such as one called Viton (TM).

Preferably, the lay-up surface comprises a main surface portion, provided with a number of attachment points for attaching raised portions on the main surface portion.

Preferably, the lay-up surface comprises a main surface 15 portion and a number of raised portions on the main surface portion.

The raised portions provide a required geometric profile to allow the layers to be layed-up and layers to abut against the raised portions so that the same required profile of the component is achieved. The required profile may be an edge with, for example, a castellated shape or may be an internal hole and/or recessed area within the component. A raised portion may comprise a dowel (for example, made of nylon) for providing a hole in the component, for example, for a rivet or other fastener.

Preferably, the raised portions comprise through-holes for attaching the raised portions to corresponding attachment points on the main surface portion. The raised portions may be attached with fasteners, such as bolts. -9 -

The tool may be provided with sensors to sense the temperature and/or pressure inside the sealed zone.

The tool may also be provided with a data recorder to record the temperature and/or pressure inside the sealed zone. The data recorded may be able to be transferred to a portable data storage device for transferring to a computer or a similar tool. The second tool may then provide the same temperature and/or pressure profile during another curing process on another component. Having a set temperature and/or pressure profile associated with the curing of the components may aid in authentication or certification of the components.

The tool may be provided with a control panel that controls the tool to provide a required temperature and/or pressure. The control panel may be a programmable interface device (such as a proportional-integral-derivative controller, for keeping the heating and cooling rates constant) to allow the tool to provide a require temperature and/or pressure profile during curing.

According to a second aspect of the invention there is also provided a tool for curing a composite component, the tool comprising a lay-up surface for laying-up layers of an uncured composite component, and a cover assembly for moving in relation to the lay-up surface to cover a layed-up uncured composite component on the lay-up surface, the cover assembly comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a -10 -sealed zone, wherein the sealable cover comprises a shaped cover that holds its shape.

The sealable cover therefore has a volume associated 5 with it for containing the uncured composite component.

Preferably, the sealable cover is shaped such that it has a lower edge region that can seal around the lay-up surface and a roof region that holds its shape to extend 10 above the lay-up surface.

Preferably, the tool further comprises at least one vacuum port for proving a vacuum to the sealed zone and wherein the sealable cover is made of flexible material such that it flexes when the vacuum is provided to the sealed zone.

Preferably, the sealable cover and/or cover assembly are made of durable materials. This allows them to be reused.

According to a third aspect of the invention there is also provided a tool for curing a composite component, the tool comprising a lay-up surface for laying-up layers of an uncured composite component, wherein the lay-up surface has a main surface portion and wherein the main surface portion is provided with a number of raised portions on the main surface portion, and/or a number of attachment points for attaching raised portions on the main surface portion.

Preferably, the raised portions are removable from the 30 main surface portion to aid laying-up of the composite -12 -component to and/or extraction of the composite component from the lay-up surface.

Preferably, the raised portions comprise through-holes 5 for attaching the raised portions to corresponding attachment points on the main surface portion. The raised portions may be attached with fasteners, such as bolts.

According to a fourth aspect of the invention there is also provided a method of manufacturing a composite component, the method including the steps of laying-up an uncured composite component on the lay-up surface of the tool of any preceding claim, curing the composite component, and extracting a cured component from the lay-up surface.

The curing process may involve the steps of heating the uncured composite component and also providing a vacuum to the uncured composite component.

According to a fifth aspect of the invention there is also provided a composite component manufactured by the method described above.

Preferably, the composite component forms at least part 25 of a piece of aircraft furniture, such as an aircraft seat shell.

It will of course be appreciated that features described in relation to one aspect of the present invention 30 may be incorporated into other aspects of the present invention. For example, the method of the invention may -13 -incorporate any of the features described with reference to the apparatus of the invention and vice versa. Also, features described in relation to one aspect of the apparatus of the present invention may be incorporated into other aspects of the apparatus of the present invention.

Description of the Drawings

Embodiments of the present invention will now be 10 described by way of example only with reference to the accompanying schematic drawings of which: Figure 1 shows a perspective view of a heat mould tool, Figure 2 shows a perspective view of a composite seat 15 shroud manufactured using the heat mould tool of Figure 1, Figure 3 shows a cross-sectional view of part of a composite tooling surface structure of the heat mould tool of Figure 1, Figure 4 shows a cross-sectional view of the heat mould 20 tool of Figure 1, Figure 5 shows a perspective view of the heat mould tool of Figure 1 with a cover open, Figure 6 shows a cross-sectional view of a section of a vacuum bag and frame of the heat mould tool of Figure 1, Figure 7 shows an exploded perspective view of the heat mould tool of Figure 1 without the cover and with an intensifier layer, Figure 8 shows a perspective view of the heat mould tool of Figure 1 without the cover and with removable nylon 30 dowels and blocks located at cut-out locations on the composite tooling surface structure, and -14 -Figure 9 shows a graph of a typical cure temperature cycle.

Detailed Description

Figures 1 and 3 to 8 show a heat mould tool 1 according to a first embodiment of the invention. The tool 1 is provided for the manufacture of composite seat shrouds 3, constructed from layers of pre-preg material, such as that shown in Figure 2. The seat shroud 3 forms the main back bone of a seat shell structure for use on an aircraft.

The tool 1 comprises a base 5 that supports a tooling surface structure 7, providing a tooling surface 8, shaped to match the desired surface profile of the composite seat shroud 3, upon which the composite seat shroud 3 is layed-up and cured, and a cover 9 that, in use, envelops and creates a sealed environment around the tooling surface 8. The tooling surface 8 is roughly 0.9 m x 1.3 m. It extends typically 100 mm beyond the desired "edge of part" of the seat shroud 3. The tool 1 has a plug (not shown) for plugging into a conventional power socket and providing power to the tool.

The tooling surface structure 7, a cross-sectional schematic of part of which is shown in Figure 3, comprises an upper-most portion of eight plies (cured at 180°C) of carbon fibre composite 11, the upper surface of the uppermost carbon fibre ply 8 providing the tooling surface 8. The upper surface 8 of the uppermost carbon fibre ply is therefore maintained with a surface finish of 0.4 um or -15 -better to ensure that the cured composite seat shroud 3 has an adequate surface finish. Below the eight plies of carbon fibre composite 11, the tooling surface structure 7 comprises a layer of tooling surface heating elements 15 (electrical heater wires) that are electrically insulated from the rest of the tooling surface structure 7 by being sandwiched between an upper layer of two glass fibre composite plies 17 and a lower layer of three glass fibre composite plies 19 (the glass fibre composite plies cured at 135°C). At the edges of the tooling surface structure 7, electrodes 28 are attached to the tooling surface heating elements 15 so that they may be connected to a power source 29 (taking power from the power socket) in the base 5 of the tool 1. The lower layer of three glass fibre composite plies 19 is painted with a thermally insulating coating 21 in order to minimise heat transfer into the base 5 of the tool 1 during the curing process.

The tooling surface structure 7 is provided with a number of removable side panels (or edge bars) 64 of the tooling surface 8 to produce a shaped edge of the cured component. The shaped edge is castellated. The tooling surface structure 7 is provided with a number of sunken portions 66 in the tooling surface 8, into which correspondingly shaped nylon rectangular blocks 63 may be placed so as to protrude above the tooling surface 8. The tooling surface structure 7 is provided with a number of rounded apertures 67 into which nylon dowels 65 may be placed. These provide rivet/fastener holes in the cured component. Thus, the tooling surface 8 is provided with inserts that cut-outs 62 in pre-preg layers can be abutted -16 -against during lay-up, thereby providing clean internal and external edges and holes in the cured seat shroud 3.

The tooling surface structure 7 is mounted on top of the base 5 of the tool 1 such that the uncured composite seat shroud 3 can be layed-up directly onto the tooling surface 8. The base 5 comprises a hollow composite box that houses a dry-vane vacuum pump 23 and the power source 29, as can be seen in the cross-section shown in Figure 4. The vacuum pump 23 is in fluid communication with a vacuum port 25 on the tooling surface 8 via a vacuum line 27. The power source 29 is connected to the electrodes 28 of the tooling surface heating elements 15. In use, the vacuum pump 23 is operated to obtain the desired vacuum pressure at the tooling surface 8 and the heating elements 15 are operated to obtain the desired temperature at the tooling surface 8. During the cure process, the tool 1 is thermally monitored by temperature sensors or thermocouples (not shown) and thermally controlled by a PID (programmable interface device) 30, such as a proportional-integral-derivative controller (for keeping the heating and cooling rates constant), the display of which is located on a first side 31 of the base 5. A pressure gauge 32 is situated on the first side 31 of the base 5 such that the vacuum pressure level at the tooling surface 8 can also be monitored (vacuum pressure sensors not shown).

There is also an emergency stop switch, switches/buttons (such as warm, vacuum, run, stop), and a 30 USE port on the side 31. The USE port can be used to input settings to the PID 30. The PID 30 is also able to store -17 -program settings, and can be controlled by a user. The USB port may also be used to export the temperature and/or pressure profile of a cure cycle so that the cycle can be reproduced on a different tool.

Forklift apertures 33 (each 21 cm x 10 cm) are located on the first side 31 and on a second opposite side 34 of the base 5, such that the tool 1 (weighing 60 kg) may be transported by a forklift (or similar) by inserting the forks of the forklift into the forklift apertures 33 located on one of the sides of the base 5, passing the forks through the interior of the base 5 and out of the forklift apertures 33 located on the other side of the base 5. Each aperture edge is covered with a rubber material to help prevent damage to the apertures 33.

Two air vents 35 (each 20 cm x 20 cm) are located on a front end 37 and on a back end 38 of the base 5 in order to encourage air flow through the interior of the base 5 and therefore cool the vacuum pump 23, power source 29, and PID 30 contained therein.

Two hinges 40 (one of which is shown in Figure 5) are located on the upper most edge of the back end 38 of the base 5, and connect the base 5 with the cover 9 of the tool 1, such that the cover 9 is pivotally mounted on the base 5 and can be opened as shown in Figure 5. Once opened, the cover 9 is held in the open position by two gas springs 41, 42; one at each side of the cover 9. Each gas spring 41, 42 comprises a piston rod 39 and a cylinder 43. The piston rod is connected to a side of the base 5 and the cylinder 43 is -18 -connected to the same side of the cover 9. The gas springs 41, 42 also prevent the cover 9 from being pushed back further than the open position (at approximately 90° to the base 5). When the tool is being used to cure the composite seat shroud 3, the cover 9 is locked in the closed position by two toggle clamps 44 that secure the front end of the cover 9 to the front end 37 of the base 5.

The cover 9 comprises a rectangular aluminium frame 45 that in the closed position sits on top of the base 5 such that the frame 45 surrounds the tooling surface 8. A flexible vacuum bagging sheet 47 spans the interior of the frame and is connected within an inner edge 48 of the frame 45 such that the vacuum bagging sheet 47 of the cover 9, when the cover 9 is in the closed position, envelops the tooling surface 8. A neoprene (or similar) seal 49 runs around the underside of the frame 45 at the interface between the frame 45 and the base 5 ensuring that when the cover 9 is in the closed position the tooling surface 8 is situated within a sealed environment, the pressure of which may be controlled by the vacuum pump 23.

A cross-sectional schematic of the frame 45 and vacuum bagging sheet 47 is shown in Figure 6. The vacuum bagging sheet 47 has a bottom layer 51 made of a synthetic rubber sold under the trademark Viton by DuPont and, in use under the pressure applied by the vacuum pump 23, is in contact with the upper surface of the lay-up of the composite seat shroud 3 on the tooling surface 8. Above the bottom layer 51, sits a layer of vacuum bagging sheet heating elements 53 distributed along the length of the vacuum bagging sheet 47 -19 -in order to provide a heat source to the upper surface of composite seat shroud 3 during the cure process. The vacuum bagging sheet heating elements 53 are connected to the power source 29 and controlled by the PID 30, both situated within the base 5 of the tool 1. The vacuum bagging sheet heating elements 53 are sandwiched between two thermally conductive heating blankets 55 that aid with the distribution of heat.

The uppermost layer of the vacuum bagging sheet 47 is a thermally insulating layer 57 that prevents heat escaping 10 from the cover 9.

The edges of the layers that comprise the vacuum bagging sheet 47 are received within a channel 58 that runs around the interior edge 48 of the aluminium frame 45 and are clamped within the channel 58 under the action of clamping screws 59 situated at intervals around the perimeter of the frame 45. Each screw 59 enters an upper side of the frame, substantially opposite the side comprising the neoprene seal 49, and act directly on a clamping plate 60 situated within the channel 58 such that the edges of the vacuum bagging sheet 47 can be clamped between the clamping plate 60 and a lower interior face of the channel 58. It is expected that the vacuum bagging sheet 47 will be capable of being used for at least 300 curing operations. It can be replaced at a suitable time.

An intensifier layer 61, shown in Figure 7, may be used to enhance the uniformity of the pressure distribution across the upper surface of the composite seat shroud 3 during the cure process. The intensifier layer 61 comprises a silicon sheet that has been moulded to match the desired -20 -profile of the upper surface of the composite seat shroud 3 and, in use, sits on top of the composite seat shroud 3 during the curing process, beneath the vacuum bagging sheet 47.

As mentioned, the tool is used in the manufacture of composite components constructed from pre-preg material, such as the composite seat shroud 3 shown in Figure 2. In use, the tooling surface 8 of the tool 1 (provided with the appropriate inserts) is prepared with a coating of a suitable release agent, such as that sold in the UK under the trademark Frekote 700-NC by Henkel Ltd., and then warmed to 45°C in order to aid the drape of the uncured pre-preg layers of the composite seat shroud 3 and facilitate the lay-up process onto the tooling surface 8. A number of cutouts 62 are located in the layers of the composite seat shroud 3, and as the layers are layed-up by hand on to the tooling surface 8, the cut-outs are lined up around the side panels/edge bars 64 and with the blocks 63 and dowels 65.

Once the uncured composite seat shroud 3 has been layed-up on the tooling surface 8, it is covered with a release film (not shown) and then the intensifier layer 61 is placed on top. A breather cloth (not shown) is then placed on top of the intensifier layer 61 in order to encourage a uniform air pressure distribution and absorb any resin that bleeds out of the edges of the shroud 3 during the cure process. The cover 9 is then moved to the closed position and locked via the clamps 44. The appropriate vacuum pressure is applied via the pump 23, typically a vacuum of 1 bar (or 29.5 inHg) is applied to de-bulk the -21 -lay-up. Furthermore, it is possible to de-bulk the uncured composite component during the lay-up process after laying each layer of the component. It is noted that the tool 1 has a maximum vacuum loss of 1 inHg per 5 minutes.

The PID 30 is programmed with the appropriate times and temperatures of the ramp-up (heating to a desired temperature at a given rate), dwell (at desired temperature for a given time) and cooling (to room temperature at a given rate) stages of the cure process as provided by the pre-preg manufacturer and the cure run cycle is started. The PID controls the temperature by controlling the heat provided by the heating elements 15 and 53. A typical cure temperature cycle with a cure temperature of 135°C is shown in Figure 9. It is noted that the heating elements 15 and 53 are capable of achieving a ramp-up rate of between 0.5 and 5 °C/min, a dwell temperature of between 25 and 150 °C with a variation of ±5°C between top and bottom surfaces of the shroud 3.

Once the cure cycle is complete and the composite seat shroud 3 has cooled sufficiently, the cover 9 is unlocked by clamps 44 and moved to the open position. The breather cloth, intensifier layer 61, and release film are removed to expose the upper surface of the cured composite seat shroud 3. The nylon blocks 63 and dowels 65 are then removed. The cured composite seat shroud 3 can then be removed from the tooling surface 8. It can then be polished around its perimeter to achieve a clean -edge of part".

-22 -Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.

A similar tool 1 may be used to produce any composite component, not just a seat shroud 3. For example, the composite component may be significantly larger or significantly smaller than a seat shroud 3 or a different shape.

The composite component may be a monolithic laminate (comprising just pre-preg layers) or a sandwich laminate (also comprising a comb structure) or a combination.

The tooling surface 8, intensifier layer 61 and cover 9 etc. may therefore be made to any suitable size/shape.

The intensifier layer 61 may be made with carbon fibre combined with silicon.

The tool 1 may be provided with any required number/shape/size of sunken portions and corresponding nylon dowels 65, blocks 63 and side panels/edge bars 64. For example, the side panels/edge bars 64 may provide a wavy or a zig-zag shape and the blocks 63 may be triangular or round.

-23 -The forklift apertures may be provided on one side of the base 5 only.

The cover 9 may be provided with a handle on one/each 5 side to aid opening and closing of the cover 9.

The tool 1 may be provided with a network cable connection so that settings can be sent to the PID 30 using the internet.

The tool 1 may be provided with rubber feet to minimize the impact when placing the tool 1 down and to ensure that the tool 1 does not shift positions.

The tooling surface structure 7 may be formed of any suitable materials and/or any number of plies of composite material.

The tool 1 may comprise a first tooling surface structure 7 which may be removed and replaced with a second tooling surface structure 7a such that two different composite components may be manufactured using the same tool 1.

The tool 1 may be provided with a number of separate tooling surfaces 8 such that a plurality of composite components may be manufactured during a single cure cycle.

Where in the foregoing description, integers or 30 elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein -24 -incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.

Claims

-25 -Claims 1. A tool for curing a composite component, the tool comprising: - a lay-up surface for laying-up layers of an uncured composite component, a cover assembly for moving in relation to the lay-up surface to cover a layed-up uncured composite component on the lay-up surface, the cover assembly comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a sealed zone, and a vacuum port for providing a vacuum to the sealed zone, wherein the tool further comprises at least one heating 15 element within the sealed zone for heating the uncured composite component.
2. A tool as claimed in claim 1, wherein the cover assembly comprises a cover heating element for heating an 20 upper side of the layed-up uncured composite component.
3. A tool as claimed in claim 2, wherein the cover heating element is attached to an underside of the sealable cover.
4. A tool as claimed in claim 2 or 3, wherein the cover heating element comprises a heating blanket formed of a wire mesh, or similar, embedded within a carrier material.
5. A tool as claimed in any preceding claim, wherein the lay-up surface comprises a surface heating element for -26 -heating a lower side of the layed-up uncured composite component.
6. A tool as claimed in claim 5, wherein the surface 5 heating element is embedded beneath a top layer of the lay-up surface.
7. A tool as claimed in any preceding claim, wherein the vacuum port is provided in the cover assembly.
°. A tool as claimed in any preceding claim, wherein the sealable cover is a shaped cover that holds its shape.
9. A tool as claimed in claim 8, wherein the sealable 15 cover is shaped such that it has a lower edge region that can seal around the lay-up surface and a roof region that holds its shape to extend above the lay-up surface.
10. A tool as claimed in any preceding claim, wherein the 20 sealable cover is supported by a frame structure.
11. A tool as claimed in any preceding claim, wherein the sealable cover is made of flexible material such that it flexes when the vacuum is provided to the sealed zone.
12. A tool as claimed in claim 11, wherein the sealable cover is made of an elastomeric material.
13. A tool as claimed in any preceding claim, wherein the 30 lay-up surface comprises a main surface portion, provided with a number of attachment points for attaching raised portions on the main surface portion.

-27 -
14. A tool as claimed in any preceding claim, wherein the lay-up surface comprises a main surface portion and a number of raised portions on the main surface portion.
15. A tool as claimed in claim 13 or claim 14, wherein the raised portions comprise through-holes for attaching the raised portions to corresponding attachment points on the main surface portion.
16. A tool for curing a composite component, the tool comprising: - a lay-up surface for laying-up layers of an uncured composite component, and - a cover assembly for moving in relation to the lay-up surface to cover a layed-up uncured composite component on the lay-up surface, the cover assembly comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a sealed zone, wherein the sealable cover comprises a shaped cover that 20 holds its shape.
17. A tool as claimed in claim 16, wherein the sealable cover is shaped such that it has a lower edge region that can seal around the lay-up surface and a roof region that 25 holds its shape to extend above the lay-up surface.
18. A tool as claimed in claim 16 or claim 17, wherein the sealable cover is supported by a frame structure.
19. A tool as claimed in claim 16, 17 or 18, wherein the tool further comprises a vacuum port for proving a vacuum to -28 -the sealed zone and wherein the sealable cover is made of flexible material such that it flexes when the vacuum is provided to the sealed zone.
20. A tool as claimed in claim 19, wherein the sealable cover is made of silicon.
21. A tool for curing a composite component, the tool comprising a lay-up surface for laying-up layers of an uncured composite component, wherein the lay-up surface has a main surface portion and wherein the main surface portion is provided with; -a number of raised portions on the main surface portion, and/or -a number of attachment points for attaching raised portions on the main surface portion.
22. A tool as claimed in claim 21, wherein the raised portions are removable from the main surface portion to aid 20 laying-up of the composite component to and/or extraction of the composite component from the lay-up surface.
23. A tool as claimed in claim 21 or 22, wherein the raised portions comprise through-holes for attaching the raised 25 portions to corresponding attachment points on the main surface portion.
24. A method of manufacturing a composite component, the method including the steps of: -laying-up an uncured composite component on the lay-up surface of the tool of any preceding claim, -curing the composite component, and -29 - -extracting a cured component from the lay-up surface.
25. A composite component manufactured by the method of claim 24.
26. The composite component of claim 25, wherein the composite component forms at least part of a piece of aircraft furniture, such as an aircraft seat shell. 1C)